Sol-gel-based composite materials for direct-write electronics applications

ABSTRACT

Sol-gel-derived “0-3 composite” ceramics are provided for application to electronics components directly written onto low-temperature substrates. The 0-3 composite materials are prepared from a mixture of liquid-phase and solid-phase constituents, as are the pastes conventionally used to prepare thick-film materials for the electronics industry. The prepared 0-3 composites exhibit several advantages, including substantial reductions in (1) processing temperatures, (2) solvent concentrations, and (3) organic post-processing-residual concentrations. In addition, the rapid removal of solvent during application is compatible with such rapid prototyping methods as laser densification. The 0-3 composites may be deposited onto plastic substrates while still meeting expected performance standards. Therefore, the direct writing of electronics components onto such low-temperature substrates as plastic may be achieved using sol-gel-based 0-3 composites. The process is useful for resistors, capacitors, insulators, inductors and conductors.

BACKGROUND OF THE INVENTION

[0001] The sol-gel process, which in the most general sense is based on inorganic polymerization reactions, is considered a unique route for the chemical synthesis of ceramic-containing materials. The process provides a low-temperature route for preparing ceramic materials with excellent homogeneity, a low sintering temperature, low impurity levels, and customizable physical features.

[0002] The wide availability of metal alkoxide precursors facilitates preparation of almost any type of ceramic composition, including some phases not achievable through conventional high-temperature processes. By combining various metal alkoxides, unique amorphous networks can be prepared in chemical compositions matching those of almost all metal oxides currently available in powder form. With such a large potential for developing numerous types of ceramic systems, sol-gel science can be utilized in almost any type of ceramics application.

[0003] The “0-3 composite” concept focuses upon the development of thick sol-gel-derived ceramic composite films. They are deposited from a solution comprised of both macroscopically liquid (sol) and particulate (aggregate) phases. The liquid portion is derived via a relatively conventional sol-gel route toward the preparation of oxide coatings. This sol phase, which contains the reactive alkoxide precursors, subsequently gels and condenses to form a matrix that entraps the particulate phase (1-2). This process is analogous to the fabrication of a brick wall, wherein the sol-gel-derived matrix acts as mortar and the entrapped oxide particles act as bricks (2).

[0004] The designation “0-3” refers to the connectivity of the elements in each phase; that is, the entrapped particulate phase exhibits no interparticle connectivity while the sol phase exhibits three-dimensional connectivity upon gelation. Thus, 0-3 composites result from a hybrid colloid particle-sol-gel suspension.

[0005] Compared to typical sol-gel processes, the 0-3 composite method produces films that (1) are orders of magnitude thicker per coating application, (2) can form with very little or no cracking, and (3) dry into more densely packed films (xerogels). These 0-3 composite films also exhibit substantially lower consolidation temperatures and better substrate adhesion than traditional paste-derived layers. For these reasons, 0-3 composites appear to be promising candidates for developing highly densified thick ceramic films at low temperatures.

[0006] Needs exist for a direct-write process for writing electronic components onto low-temperature plastic substrates. That need is addressed by the inventive sol-gel-based 0-3 composite process described in the ongoing specification. The present inventors have achieved surprising results by combining the sol-gel process and the 0-3 composite process.

SUMMARY OF THE INVENTION

[0007] Sol-gel-derived “0-3 composite” ceramics are being developed under the DARPA MICE (Defense Advanced Research Project Agency, Mesoscopic Integrated Conformal Electronics) program for application to electronics components directly written onto low-temperature substrates.

[0008] The 0-3 composite materials are prepared from a mixture of liquid-phase and solid-phase constituents, as are the pastes conventionally used to prepare thick-film materials for the electronics industry. When compared with conventional paste materials and processes, however, the new 0-3 composites exhibit several potential advantages, including substantial reductions in (1) processing temperatures, (2) solvent concentrations, and (3) organic post-processing-residual concentrations.

[0009] In addition, the rapid removal of solvent during application is compatible with such rapid prototyping methods as laser densification. Preliminary results of the CMS-OSU MICE project clearly indicate that 0-3 composites may be deposited onto plastic substrates while still meeting expected performance standards. Therefore, the direct writing of electronics components onto such low-temperature substrates as plastic may be achieved using sol-gel-based 0-3 composites. The inventive process is useful for resistors, capacitors, insulators, inductors and conductors.

[0010] These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification and the claims.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0011] The developing of low-temperature resistor materials was based on the combination of concepts from both 0-3 composite and aerospace paint technologies. The 0-3 composites, derived from a solution containing both liquid (sol) and particulate phases, yields thick oxide films which may be prepared at low temperatures without developing such structural defects as cracks.

[0012] The essential concept in such a system is that the liquid phase, mainly composed of a reactive metal alkoxide, is chemically converted into a metal oxide upon exposure to water. One disadvantage to such precursors is that resistor materials based on ruthenium (chiefly ruthenium(IV) oxide) readily react with alcohols, major byproducts of metal alkoxide hydrolysis. To overcome these reactivity issues, aerospace paint technology was incorporated in the 0-3 composite synthesis to eliminate organic moieties.

[0013] Satellite thermal-control coatings (white paints), which generally consist of zirconium(IV) oxide particles suspended in a potassium silicate glass matrix, are conceptually identical to 0-3 composites. The substitution of potassium silicate glass for the metal alkoxide yields a binder phase that becomes more reactive and more able to form a rigid three-dimensional network upon solvent loss.

[0014] The unique advantages of using potassium silicate glass in a resistor formulation are (1) low processing temperatures and (2) the ability to use RuO₂ particles without risking metal reduction (RuO₂ readily undergoes redox reactions with alcohols). Therefore, through this blend of 0-3 composite and aerospace coating technologies, a ruthenium-based resistor may be constructed and processed at extremely low relative temperatures.

[0015] The capacitor materials developed for the MICE program by CMS and OSU are based solely on 0-3 composite technology. Pastes of dielectric materials with both low and high dielectric constant (κ) values were formulated by mixing selected dielectrics into specific metal alkoxide precursors. The cardinal attributes associated with the selection of metal alkoxide precursors were (1) compositional compatibility with the powder used, (2) reactivity with water, (3) physical properties (liquid or solid), and (4) thermal-decomposition properties.

[0016] Metal alkoxides with compositional compatibility were used to improve or maintain κ values. The use of chemically identical binder and filler phases yields homogenous compositions capable of producing more stable films with higher κ values. The reactivity of the alkoxide precursors was chosen so that they could be hydrolyzed easily upon exposure to ambient humidity. Increased reactivity provides a way to reduce the residual concentrations of organics, thereby lowering the potential for dielectric losses.

[0017] The physical properties of the metal alkoxides were chosen so that the molecular precursors could also act as solvents, thereby reducing or eliminating the need for organic solvents. Finally, precursors with low thermal or photoinitiated decomposition thresholds were preferred because such decompositions provide a means to control powder packing efficiency, lower processing temperatures, and lower the potential for organic contamination. By incorporating all four attributes, CMS and OSU have been able to develop, at low temperatures, capacitor, resistor, inductor and conductor materials with exceptional performance.

[0018] The accomplishments of CMS and OSU in their direct-write sol-gel-derived 0-3-composite-materials project include the complete construction of several different microelectronics devices. Resistor, capacitor, conductor and inductor materials have all been prepared using sol-gel-based processes. The resistor and inductor materials were prepared by combining potassium silicate-based precursors with selected composite powders, while the capacitor materials were prepared by combining various silicate, titanate, and barium titanate precursors.

[0019] In each system, specific precursors were chosen based on reactivity, physical state, and compatibility with the composite powders. Work is continuing towards improvements in performance and such physical properties as adhesion, morphology, density, and the elimination of structural defects, if any.

[0020] While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims. 

We claim:
 1. A method for producing electronic components comprising preparing a composite material using a sol-gel process in combination with a 0-3 composite process thereby forming the electronic components.
 2. The method of claim 1 , wherein the preparing the composite material further comprises converting a liquid phase into a metal oxide in the presence of water.
 3. The method of claim 2 , wherein the liquid phase comprises at least one reactive metal alkoxide.
 4. The method of claim 3 , wherein the at least one reactive metal alkoxide is a ruthenium based oxide.
 5. The method of claim 4 , wherein the ruthenium based oxide is ruthenium (IV) oxide.
 6. The method of claim 2 , further comprising a thermal-control coating.
 7. The method of claim 6 , wherein the coating comprises zirconium (IV) oxide particles.
 8. The method of claim 7 , further comprising a potassium glass matrix, wherein the zirconium (IV) oxide particles are suspended in the matrix.
 9. The method of claim 8 , further comprising forming a binder phase with increased reactivity thereby forming a structure having a rigid three-dimensional network when a solvent in the liquid phase ablates.
 10. The method of claim 9 , wherein the structure is a low-temperature resistor.
 11. The method of claim 3 , further comprising forming a paste of at least one dielectric material and mixing the paste with the metal alkoxide.
 12. The method of claim 11 , further comprising more than one dielectric material, wherein the dielectric material has low and high dielectric constant values.
 13. The method of claim 12 , wherein the metal alkoxide functions as a precursor and improves or maintains the dielectric constant values.
 14. The method of claim 13 , further comprising chemically identical binder and filler phases for producing composites with higher dielectric constant values.
 15. The method of claim 13 , further comprising hydrolyzing the precursors by exposing to ambient humidity.
 16. The method of claim 3 , wherein the metal alkoxide act as solvents thereby reducing or eliminating use of organic solvents.
 17. The method of claim 3 , wherein the metal alkoxide has low thermal or photo decomposition threshold for controlling a powder packing efficiency, lowering processing temperatures, and lowering potential for organic contaminations.
 18. The method of claim 1 , wherein the preparing the composite material comprises combining potassium silicate based precursors with selected composite powders thereby forming resistor and inductor materials.
 19. The method of claim 1 , wherein the preparing the composite material comprises combining precursors selected from the group consisting of silicate, titanate and barium titanate thereby forming capacitor materials.
 20. The method of claim 3 , wherein the electronic components comprises resistors, capacitors, conductors and inductors. 